TITLE: Compact, Flexible
Integrated Power Node Center for Direct Current Distribution
Battlespace, Electronics, Sensors
ACQUISITION PROGRAM: PMS 320,
Electric Ships Office
The technology within this
topic is restricted under the International Traffic in Arms Regulation (ITAR),
22 CFR Parts 120-130, which controls the export and import of defense-related
material and services, including export of sensitive technical data, or the
Export Administration Regulation (EAR), 15 CFR Parts 730-774, which controls
dual use items. Offerors must disclose any proposed use of foreign nationals
(FNs), their country(ies) of origin, the type of visa or work permit possessed,
and the statement of work (SOW) tasks intended for accomplishment by the FN(s)
in accordance with section 5.4.c.(8) of the Announcement. Offerors are advised
foreign nationals proposed to perform on this topic may be restricted due to
the technical data under US Export Control Laws.
OBJECTIVE: Develop a compact,
modular, galvanically isolated, Direct Current (DC) distribution Integrated
Power Node Center (IPNC) to supply mission-critical equipment with
high-quality, uninterruptible power.
Future Navy ships will include mission critical equipment
with DC interfaces in addition to traditional 60Hz and 400Hz systems. Development of this compact DC power distribution
Integrated Power Node Center (IPNC) will avoid costly, custom solutions needed
to address each particular load.
IPNCs are being employed for replacing existing 400Hz Alternating Current (AC)
power systems onboard U.S. Navy amphibious ships and destroyers, which
currently use centralized and redundant frequency conversion.
Currently the 400Hz power (defined by MIL-STD-1399) is generated in centralized
locations and then distributed via a combination of load centers, cabling,
Automatic Bus Transfers (ABTs), transformers, and power panels to numerous
loads located throughout the ship. This traditional distribution system
approach leads to the placement of large and expensive frequency converters at
strategic locations onboard the ship and significant distribution components,
requiring long cable runs. A more effective and survivable approach would
utilize the existing 60Hz distribution system to provide power to compact IPNCs
located directly at the load site.
The Navy is now moving towards DC distribution, so it is desired to use this
approach for new voltages consistent with the “Naval Power and Energy Systems
Technology Development Roadmap”  to reduce the costs and maintenance
associated with centralized conversion and multiple parallel distribution
systems for each interface. This innovative compact DC distribution IPNC will
enable uninterruptible power using multiple power sources and minimize
dedicated energy storage. The only energy storage required will be to hold
existing loads while the power system reconfigures. This compact DC
distribution IPNC needs to be designed so that only output modules are replaced
to accommodate changes in power requirements for upgrades and changes to
weapons and sensors during the ship’s service life. The ability to reconfigure
IPNC redundant input sources and selectable output voltages will enable a
common solution across multiple system loads and ship types.
The Navy seeks to develop a compact, modular, galvanically isolated DC
distribution IPNC that consists of an enclosure and dual input voltages of
1000VDC and 440VAC, output voltages of 650VDC, 375VDC, 440VAC at 60Hz and 400Hz
3 phase, and energy storage interface modules capable of supporting aggregate
loads of up to 300kW that meet DC interface specifications and
MIL-STD-1399-300B. The goal is to reduce total ownership costs with reduced
acquisition, integration, and maintenance costs associated with separate
distribution systems and improve reliability and performance by virtue of
simplified and flexible electrical distribution system architecture.
The Navy desires a compact DC distribution IPNC whose size, weight, and cost
would enable placement in proximity to the load site with minimal ship
integration impact. The IPNC should be able to pass through a
26"x66" oval opening and be mountable on a ship’s bulkhead for
arrangement flexibility. Power densities for the proposed solution shall have a
threshold of two Megawatt per cubic meter with an objective of three Megawatt
per cubic meter. Proposed concepts will need to address load survivability
during system electrical faults and power interruptions by limiting current and
being capable of seamless switching to alternate supply power sources. Compact
DC distribution IPNC modules should be able to isolate faults at the load site,
without affecting adjacent loads or the rest of the electrical distribution
system. Furthermore, these modules must protect the load from upstream
anomalies such as high harmonics and input voltage swings exceeding a ±10
percent fluctuation. The goal is to preserve power to the loads such that when
the loads have two sources of power, the loss of one source will not cause a
power interruption to the load. The compact DC distribution IPNC modules need
to be designed with sufficient efficiency to allow air-cooling while
maintaining power quality requirements.
Recent Navy experiences with power conversion-based systems have demonstrated
challenges associated with common mode and line-ground performance under a
variety of normal and fault situations. The compact DC distribution IPNC must
be compatible with ungrounded naval power systems and therefore be capable of
continued operations with the input or output interfaces ungrounded, ungrounded
but faulted to ground, or grounded. Internal failures of compact DC
distribution IPNCs should not cause adverse line-line or line-ground voltages
or currents on the inputs or outputs. Each interface point should have
isolation from the other interface points (Input A, Input B, Output X, Output,
Y, etc.) to preclude common mode voltages and currents, or line-ground voltage
excursions from influencing the other interfaces.
Reliability and maintainability is of critical importance as the IPNC is a
point of use converter. A failure of the IPNC can result in the loss of
mission-critical equipment functionality. The IPNC offered should include
concepts with extremely high reliability or modularly to increase the
reliability and maintainability. IPNC needs to meet a 20,000 hour mean time
between service interruptions. It should be noted, that if a repair requires
the unit to stop providing output power, then the repair will be considered a
Proposed compact DC distribution IPNC module concepts should meet the
applicable performance goals converters in MIL-PRF-32272, Performance
PHASE I: Develop a concept
for a compact, modular, galvanically-isolated DC distribution IPNC capable of
providing high-quality, high-reliability, uninterruptable power that meets the
topic requirements. Demonstrate the feasibility of the concept in meeting Navy
needs and transitioning into a useful product for the Navy. Demonstrate
feasibility on a component or Lowest Replaceable Unit level. The Phase I
Option, if awarded, will address technical risk reduction and provide
performance goals and key technical milestones. Phase I will include prototype
plans to be developed under Phase II.
PHASE II: Based on the
results of Phase I and the Phase II Statement of Work (SOW), develop and
deliver one or more full-scale prototype(s) to the Navy for evaluation.
Evaluate the prototype(s) to determine its (their) capability in meeting the
performance goals defined in the Phase II SOW and the Navy requirements for the
compact, modular, galvanically-isolated DC distribution IPNC. Demonstrate
system performance through prototype evaluation and modeling or analytical
methods over the required range of parameters. Use evaluation results to
refine the prototype into a producible design that will meet Navy
requirements. Conduct performance integration and risk assessments; and
develop a cost-benefit analysis and cost estimate for a naval shipboard unit.
Prepare a Phase III development plan to transition the technology to Navy use.
PHASE III DUAL USE
APPLICATIONS: Support the Navy in evaluating the prototypes delivered in Phase
II and the transition of the technology to Navy use. Based on analysis
performed during Phase II, recommend test fixtures and methodologies to support
environmental, shock, and vibration testing and qualification. Determine,
jointly with the Navy, appropriate systems for integration into Naval Power
Systems for the components developed under this SBIR topic for operational evaluation,
including required safety testing and certification. Working with the Navy and
applicable Industry partners, demonstrate the compact DC distribution IPNC on a
relevant shipboard system to support naval power systems. Provide detail
drawings, models, and specifications in a defined format; perform an Electrical
Safety Device evaluation; and document the final product.
Transition opportunities for this technology include power conversion units
that power directed energy, specialized loads, and for ship-wide stable backup
power systems. Power conversion units such as these can be used by renewable
energy plants, private and public utilities, industrial data centers, and a
wide range of back-up systems. Low-voltage DC power conversion will become more
prevalent as more systems shift to DC. High-power quality units will be
required to provide power to these loads.
1. “The 2015 Naval Power and
Energy Systems Technology Development Roadmap.” http://www.navsea.navy.mil/Portals/103/Documents/Naval_Power_and_Energy_Systems_Technology_Development_Roadmap.pdf
2. Doerry, Norbert.
“Electrical Power System Considerations for Modular, Flexible, and Adaptable
Ships." ASNE EMTS 2014, Philadelphia, PA, May 28-29, 2014. http://doerry.org/norbert/papers/20140412doerryEMTS2014.pdf
3. “20 -- Request for Information
for Electrical Interface Standards for Naval DC Power Systems.” http://www.fbodaily.com/archive/2016/11-November/10-Nov-2016/FBO-04323946.htm
KEYWORDS: Integrated Power
Node Center; Power Quality; Power Density; Flexible Electrical Distribution
System Architecture; Navy Ship DC Distribution; Uninterruptible Power Supply
** TOPIC NOTICE **
These Navy Topics are part of the overall DoD 2018.1 SBIR BAA. The DoD issued its 2018.1 BAA SBIR pre-release on November 29, 2017, which opens to receive proposals on January 8, 2018, and closes February 7, 2018 at 8:00 PM ET.
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